Lincoln Electric Tandem MIG Torch Operating instructions

Lincoln Electric
Brand
Lincoln Electric
Model
Tandem MIG Torch
Category
Welding System
Type
Operating instructions
Tandem MIG Torch
OPERATOR’S MANUAL
IM666-A
February, 2005
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
G3494-2, 3, 4, 5, 6
G3494-2A, 3A, 4A, 5A, 6A
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
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Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
vivi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Description..............................................................................................................A-2
Design Summary..................................................................................................................A-2
Case Assembly ....................................................................................................................A-3
Consumables .......................................................................................................................A-3
Mounting Brackets................................................................................................................A-3
Liner Installation and Trimming Instructions.........................................................................A-4
Contact Tip and Gas Nozzle Installation ..............................................................................A-4
Connecting the Torch to the Welding Equipment.................................................................A-4
Water Cooling Equipment ....................................................................................................A-5
Mounting the Torch ..............................................................................................................A-6
Work Leads ..........................................................................................................................A-7
Seam Tracking .....................................................................................................................A-7
Welding with Multiple Tandem MIG Systems.......................................................................A-7
Wire Straighteners................................................................................................................A-7
Tail Gas Coverage ...............................................................................................................A-7
________________________________________________________________________________
Operation.........................................................................................................................Section B
Electrodes and Equipment ...................................................................................................B-1
Making a Weld......................................................................................................................B-1
Avoiding Wire Feeding Problems .........................................................................................B-1
Shielding Gas Delivery .........................................................................................................B-1
Air Blast Cleaning.................................................................................................................B-1
Nozzle Reaming Stations .....................................................................................................B-1
Anti-Spatter Spray ................................................................................................................B-1
________________________________________________________________________________
Accessories.....................................................................................................Section C
General Options / Accessories..............................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Maintenance..........................................................................................................D-1
Torch Shield Replacement ....................................................................................D-1
Contact Tip Replacement......................................................................................D-2
Liner Replacement ................................................................................................D-2
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________
Parts List ..............................................................................................................P210-P
________________________________________________________________________
A-1
INSTALLATION
TANDEM MIG TORCH
A-1
TECHNICAL SPECIFICATIONS - Tandem MIG Torch
Product Number
G3494-2, 2A
G3494-3, 3A
G3494-4, 4A
G3494-5, 5A
G3494-6, 6A
Gun Cable Length
4 ft (1.2 m)
6 ft (1.8 m)
8 ft (2.4 m)
10 ft (3.0 m)
12 ft (3.6m)
65 scfh (31 liters/min) minimum
.45 gal/min at 40 psi
(1700 ml/min at 2.7 bar)
Tandem MIG Torch Cable Length Availability
Shielding Gas Flow Rate
Water Cooling Flow Rate for each Power Cable
HEIGHT WIDTH DEPTH WEIGHT
17.54 in. 3.75 in. 4.5 in. (w/o bracket) 14.0 lbs (w/ 4 ft. cable)
445.5 mm 95.3 mm 114.3 mm (w/o bracket) 6.4 kg. (w/ 4 ft. cable)
PHYSICAL DIMENSIONS
.45 gal/min at 40 psi
(1700 ml/min at 2.7 bar)
Water cooling flow rate for nozzle/gas cable
0.035" to 5/64" (0.9 mm to 1.9 mm)
Lead Electrode size
0.035" to 5/64" (0.9 mm to 1.9 mm)
Trail Electrode size
100% at 450 amps per side / 900 amps Total
Maximum current draw per electrode 650 amp / 60% duty cycle
Duty Cycle
A-2
INSTALLATION
TANDEM MIG TORCH
A-2
GENERAL DESCRIPTION
The Tandem MIG torch delivers two wire electrodes to
the weld pool. The wires are insulated from each other
for the purpose of independent arc regulation. When
welding, the wires or arcs are oriented one behind the
other. The torch provides a small but rugged housing
for delivering the two wires and it provides secure
delivery of the shielding gas. Each side of the torch is
rated for 450 Amps, 100% duty cycle with argon mix
shielding gases.
The 900 amp Tandem MIG torches are supplied in
two different configurations, the G3494-2 thru -6, (sin-
gle gas delivery configuration) and the G3494-2A thru
-6A (dual gas delivery configuration). The G3494-2
thru -6 is configured to be used with .035"-.052" diam-
eter electrodes. Shielding gas delivery is by a single
gas hose that delivers gas to the torch body. Internal
to the torch body the gas is split and delivered to the
two gas diffusers.
The G3494-2A thru -6A model is configured for .035"-
5/64" diameter wires. The G3494-2A thru -6A design
provides larger volumes of gas for gas shielding of the
welding arcs and weld pool. Gas is delivered through
the two welding power cable assemblies of the
G3494-2A thru -6A; each assembly receives separate
shielding gas from the two separate wire feeder sole-
noids. The dual source of gas provides additional gas
volume needed for proper gas shielding of larger weld
pools.
The torch can be operated bi-directionally, or even as
a single wire torch as the need arises.
The Tandem MIG torch is not factory equipped with a
feeder end connector. Use a K489-7 Fast-Mate
adapter kit (see ACCESSORIES section) to attach the
torch to the feeders. A K1500-1 gun connector must
be installed in addition to the K489-7 Fast-Mate
adapter, when using a Power Feed 10R Wire Feeder.
Liners are not included with the torch and must be
ordered separately (see ACCESSORIES section).
The torch is suitable for welding with Lincoln solid wire
steel MIG wires and metal core electrodes, from .035"
to 5/64" (0.9 mm to 1.9 mm) diameter.
Argon based shielding gases are recommended.
100% CO
2
is not recommend because of the higher
spatter levels associated with the gas.
DESIGN SUMMARY
The case, internal components and cables are the
main sub-assemblies of the torch.
TORCH CASE
The case is made from several pieces fabricated from
aluminum. The aluminum parts offer rigidity, strength
and resistance to heat and spatter. The main housing
is drilled and tapped for easy mounting to fixturing
equipment. For automation and robotic applications,
the barrel of the torch is removable and replaceable
without having an effect upon the existing tool center
point.
INTERNAL ASSEMBLY
Figure 1 Internal Assembly
All of the internal components are over molded with a
high temperature epoxy material. The over molding
rigidly holds all the parts in place while simultaneously
insulating the sub-assemblies. Each "subgun" in the
torch is electrically isolated from all other components
and individually water cooled. Separate water cooling
circuits minimize corrosion from electrical or galvanic
action.
Each face on the subguns where the diffuser engages
the torch is milled at a precise angle. The angle helps
to keep the ends of the wires close together while
allowing the use of standard contact tips. The slight
bend also creates good electrical contact between the
wire electrode and the tip.
A-3
INSTALLATION
TANDEM MIG TORCH
A-3
CABLE ASSEMBLY
Three cable assemblies deliver the necessary power
and cooling fluids to the torch.
a) G3494-X Series:
Two of the cable assemblies supply power, wire and
water cooling to each side of the torch. The third
bundle is made up of the nozzle water cooling
hoses, the air blast line and the shielding gas line.
b) G3494-XA Series:
Two of the cable assemblies supply power, wire,
shielding gas and water cooling to each side of the
torch. The third bundle is made up of the nozzle
water cooling hoses and the air blast line.
Torch liners must be ordered separately (see ACCES-
SORIES section). Customers who choose to run with
different size wires in the lead and trail must use the
correct liner for each wire.
CONSUMABLES
Heavy duty contact tips (KP2020 and KP2021 series)
are recommended for all welding applications (see
ACCESSORIES section). Standard or tapered contact
tips should only be considered in special applications
operating at low power.
Use only Tandem MIG diffusers with the Tandem MIG
torch (see ACCESSORIES section). The Tandem
MIG diffusers feature a narrow profile that prevents
internal short circuits.
All of the gas nozzles (see ACCESSORIES section)
also feature internal water cooling to assure a long life
of the torch and nozzle. Water cooling of the nozzle
reduces spatter accumulation. Nozzles are available
for welding in locations where space is restricted while
other nozzles are suitable for high deposition welding.
Inside each nozzle is a shield to prevent spatter from
bridging from the diffusers to the nozzle wall. The
shield is made from a high temperature, glass-epoxy
composite, or ceramic high temperature glass.
MOUNTING BRACKETS
A bracket for mounting the torch to a robot is available
(see ACCESSORIES section). The bracket features
an insulating plate to electrically isolate the torch from
other equipment. The insulating plate also serves as
a breakaway piece in the event of a severe collision.
A-4
INSTALLATION
TANDEM MIG TORCH
A-4
LINER INSTALLATION AND
TRIMMING INSTRUCTIONS
a) Lay the torch and cable on a flat surface and
straighten the cables.
b) With a 12 mm open-end wrench, unscrew the nut
on the cable connector that restrains the liner.
Remove the nozzle, and then remove both dif-
fusers.
c) Remove the old liners.
d) Insert the new untrimmed liners into the connector
end of the cable. Be sure the liner is of the correct
size and type as stenciled on the liner bushing.
e) Screw the nut on to the cable connector. Snug,
but do not overtighten.
f) Be sure the cable is still straight, and then trim the
liner so that 0.3 inch (6.5mm) of the liner extends
past the end of the torch. Remove any burrs from
the end of the liner.
g) Screw the gas diffusers onto the torch and tighten.
CONTACT TIP AND GAS NOZZLE
INSTALLATION
a) Choose the correct size contact tip for the elec-
trode being used (wire size is stenciled on the side
of the contact tip) and screw it snugly into the gas
diffuser.
b) Select the gas nozzle that best suits the welding
application. Inspect the o-rings on the nozzle for
cuts or tears, and replace if necessary. Examine
the nozzle shield and make sure it is free of spatter
and welding debris. Slide the nozzle onto the torch
and secure it into position with the threaded collar.
CONNECTING THE TORCH TO THE
WELDING EQUIPMENT
(See Figure 2)
There are three cable bundles for the Tandem MIG
torch.
a) G3494-X Series:
Two of the cable assemblies supply power, wire and
water cooling to each side of the torch. The third
bundle is made up of the nozzle water cooling
hoses, the air blast line and the shielding gas line.
b) G3494-XA Series:
Two of the cable assemblies supply power, wire,
shielding gas and water cooling to each side of the
torch. The third bundle is made up of the nozzle
water cooling hoses and the air blast line.
Both the G3494-X and the G3494-XA series torches
require a K489-7 Fast-Mate adapter to connect the
torch to wire feeder. When connecting to a Power
Feed 10R wire feeder a K1500-1 gun connector must
be installed at feeder before installing K489-7 Fast-
Mate adapter.
a) Check that the drive rolls and feeder guide tubes
are appropriate for the electrode size and type
being used.
CONNECTION DIAGRAM
For G3494-2 thru -6 and G3494-2A thru -6A
FIGURE 2
To Lead Water cooler
To Lead Water cooler
To Lead Wire Feeder
To Lead Wire Feeder
and Shielding Gas
Solenoid
To Trail Wire Feeder
and Shielding Gas
Solenoid
To Trail Wire Feeder
To Trail Water cooler
To Trail Water cooler
To Shielding Gas
No Hose
To Air Blast
To Air Blast
To Nozzle Water cooler
To Nozzle Water cooler
G3494-2 thru -6
G3494-2A thru -6A
A-5
INSTALLATION
TANDEM MIG TORCH
A-5
b) Push the end connector from torch into K489-7
Fast-Mate adapter on the wire feeder, and then
tighten the locking nut. Do this for both of the torch
power cables.
c) Attach the water lines from the torch power cables
to a supply of cooling water.
d) Connect the water lines from the nozzle bundle to
the Tandem MIG interface. If a Tandem MIG
interface is not used, connect the water lines
directly to the water cooler or other type of con-
troller.
e) For G3494-X Series:
Connect the shielding gas line from the nozzle
bundle to the Tandem MIG interface. Alternatively,
connect the shielding gas line to the lead wire
feeder. Do not connect the shielding gas line to
trail wire feeder, because there would be no shield-
ing gas in the event of a delayed trail arc start .
For G3494-XA Series:
Shielding gas connection was completed in step b,
when torch cables were connected to Fast-Mate
connector. Check gas hose connection from wire
feeder solenoid to Fast-Mate connector for both
the lead and trail wire feeders.
f) Attach the air blast line to the high pressure dry air
supply (50-100 psi).
Water Cooling Equipment
FIGURE 3
WATER COOLING EQUIPMENT
(See Figure 3)
The Tandem MIG torch requires three separate water
coolers for proper cooling of the torch. The lead and
trail part of the torch each require a water cooler as
well as a third cooler for the nozzle. The three coolers
maintain proper temperatures in the torch even at
maximum rated output and duty cycle, leading to long
parts life and consistent welds. The separate coolers
eliminate the risk of any current leakage through the
water.
The water cooler for the nozzle should be pro-
grammed to turn on only during welding and remain
on for twenty seconds after the weld is complete.
Automatic control of the cooler minimizes the risk of
an operator removing the nozzle and getting sprayed
by the cooling fluid.
To maximize the life of the water coolers, the coolers
for the lead and the trail part of the torch should turn
on during welding and remain on for 60 seconds after
the weld is complete.
Water cooler manufacturers often specify additives
such as fungicides or alkalides. Follow manufacturers
recommendations to achieve proper operation and
long lifetimes without clogging.
K1536-1 Flow sensors should be placed in the return
line of each water circuit. Use a KP1529-1 connector
kit to attach the flow sensors as needed.
A-6
INSTALLATION
TANDEM MIG TORCH
A-6
MOUNTING THE TORCH
Always insulate the torch from any equipment or
fixturing. Use M19190 Bracket Arm to Torch Body
Insulator if necessary. (See Figure 4, Torch mounting
dimensions)
Check to make sure the cables are free to flex and do
not get tangled or caught on other equipment. Do not
let the cables drag on moving or hot parts.
Use a collision sensor if there is a risk that the torch
may impact an object when the torch or work piece
moves.
The case of the torch has holes drilled on the back,
left and right sides for mounting the insulator on either
the back or side of the torch. All of the holes are
drilled and tapped for #10-24x.50 screws.
Torch Mounting Dimensions
FIGURE 4
M19190
WIRE STRAIGHTENERS
Use a wire straightener with each wire drive. Failure
to use a wire straightener may result in inconsis-
tent welds and weld bead placement.
TAIL GAS COVERAGE
The Tandem Mig process is capable of establishing
wide weld bead profiles at higher than usual travel
speeds. When performing large weldments at these
high travel speeds the weld pool may become unpro-
tected while cooling as the welding torch providing the
shielding gas travels faster than the pool cools. To
provide weld pool protection during these applications
it is recommended to use the trailing gas assembly
(M18408-5) to provide additional shielding.
A-7
INSTALLATION
TANDEM MIG TORCH
A-7
WORK LEAD
Minimize the length of the electrode and work lead
cables. Do not exceed 50 ft (15m) of combined elec-
trode and work lead length.
To make the work lead connection, run a properly
sized lead from the work connection on the power
source directly to the fixture. The ground connection
should be as close to the part to be welded as possi-
ble. Do not combine work leads from the lead and
trail power source. Each machine requires an indi-
vidual work lead to the welding fixture.
Do not tightly bundle the electrode leads or the
work leads together. Welding performance may
deteriorate.
SEAM TRACKING
Seam tracking is required if the joint position wanders
or varies from part to part. Most optical and mechani-
cal trackers are compatible with Tandem MIG. Check
the manufacturer’s specifications for the seam track-
ing equipment. Do not exceed the rated power limit for
the seam tracking unit.
Through-the-arc-seam-tracking (TAST) works with
Tandem MIG in the same manner as single wire
TAST. Perform the current sensing for TAST on the
lead electrode.
WELDING WITH MULTIPLE
TANDEM MIG SYSTEMS
Special care must be taken when more than one
Tandem MIG torch is welding simultaneously on a sin-
gle part. Arc blow and arc interference may occur or
be magnified.
Every torch requires a separate shielding gas regula-
tor for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or
more torches from only one regulator.
Use one work lead per power source to connect the
work stud to the welding fixture. Do not combine all
of the work leads into one lead. Performing welding
in the direction away from the work leads. For exam-
ple, if there are two Tandem MIG systems welding on
the same part, there should be four work leads (two
lead and two trail power sources.)
B-1
OPERATION
TANDEM MIG TORCH
B-1
ELECTRODES AND EQUIPMENT
TheTandem MIG torch has been designed for use
with 0.035" through 5/64" (0.9 mm to 1.9 mm) Lincoln
solid steel MIG wires and metal core wires. Refer to
the appropriate Lincoln Process and Procedure
Guidelines for further information on welding settings.
MAKING A WELD
• When using an open arc process, it is
necessary to use correct eye, head
and body protection.
------------------------------------------------------------------------
a) Check to make sure the welding power sources
are turned on and set to the correct parameters
and programs.
b) Verify that the shielding gas supply is on and set
for the correct flow rate.
c) Set the preflow and postflow times the same on
both wire feeders. Make sure the post flow is long
enough to provide shielding during any crater fill
operation.
d) Check that all of the water coolers are operating
properly.
e) If applicable, make sure the Air-Blast spray sys-
tem is on.
f) Position the torch over the joint.
• Automatic equipment may start unexpectedly.
------------------------------------------------------------------------
g) Make a weld by sending a trigger signal to the
welding power sources.
AVOIDING WIRE FEEDING
PROBLEMS
Wire feeding problems can be avoided by observing the
following procedures:
a) Do not use a torch with cables longer than neces-
sary.
b) Do not kink or pull the cable around sharp corners.
c) Keep the cable as straight as possible when welding
or loading electrode through the cable.
d) Do not allow dolly wheels or trucks to run over
cables.
e) Use only clean, rust-free electrodes. Electrodes
manufactured by Lincoln Electric have proper surface
lubrication.
f) Replace the contact tips when the arcs start to
become unstable or the contact tip ends are fused or
deformed.
SHIELDING GAS DELIVERY
Adjust flow regulators for prescribed gas flow. Inspect
hoses regularly for worn or torn hoses. Perform a soapy
water test on hoses if a leak is suspected. Avoid kinking
or collapsing hoses with cable clamps. Insure that dif-
fuser is properly seated and tight. For G3494-XA series
torch, two gas sources are required. Do not attempt
to “Y” or Tee gas from one flow meter or regulator.
AIR BLAST CLEANING
The welding torch is equipped with a separate gas hose
for the purpose of providing a high pressure air blast
through the nozzle area to clear loose spatter that may
have accumulated between the two diffusers.
The high-pressure air is routed through the torch over
molded assembly and exits into the nozzle through an
opening in the nozzle shield. Air should be dry and free
of oil or anti- spatter compound. Pressure should be ade-
quate to free loose spatter (50-100 psi).
NOZZLE REAMING STATIONS
During robotic applications a reamer should be employed
to keep the nozzle clean. Reaming the nozzle between
welds will reduce the down time associated with manual
torch cleaning. The M18426-1 reaming station is an
option that is recommended for nozzle cleaning.
ANTI- SPATTER SPRAY
Anti-spatter compound may be used to keep weld spatter
from accumulating in the nozzle. Anti-spatter should not
be applied through the air blast line. Only dry air should
be used for air blast functions.
Anti-spatter may be applied to the interior of the nozzle
from an external sprayer. The M18426-1 reaming station
comes equipped with an external anti-spatter spraying
station.
Care should be taken to apply the right amount of anti-
spatter to the internal area of the nozzle. Too much anti -
spatter will cause diffuser clogging and weld porosity.
Only a very light covering of anti-spatter is required to
keep the spatter from cling to the nozzle.
WARNING
WARNING
C-1
ACCESSORIES
C-1
GENERAL OPTIONS /
ACCESSORIES
The following options/accessories are available for
your Tandem MIG Torch from your local Lincoln
Distributor.
K489-7 Connector Kit - Magnum Fast-Mate
Adapter
Liners
Steel, Stainless and Metal Cored Electrodes
S24198-10 .035-.045" / 0.9-1.2mm, 9 ft.(2.7m)
S24198-12 .035-.045" / 0.9-1.2mm, 15 ft.(4.6m)
S24198-11 .052-.078" / 1.3-2.0mm, 9 ft.(2.7m)
S24198-13 .052-.078" / 1.3-2.0mm, 15 ft.(4.6m)
Diffusers
M19186 Diffuser
Contact Tip
Steel, Stainless and Metal Cored Electrodes
KP2020-7B1 .030” / 0.8mm
Contact Tips (Heavy Duty)
Steel, Stainless and Metal Cored Electrodes
KP2021-1B1 .035" / 0.9mm
KP2021-6B1 .040" / 1.0mm
KP2021-2B1 .045" / 1.2mm
KP2021-3B1 .052" / 1.3mm
KP2021-4B1 1/16" / 1.6mm
KP2021-5B1 5/64" / 2.0mm
Gas Nozzles
S24198-1 1 1/2” x 3/4” (37mm x 19mm)
contact tips recessed 1/8" (3mm)
S24198-2 1 1/2” x 3/4” (37mm x 19mm)
contact tips extended 1/8” (3mm)
S24198-3 1 1/2” x 7/8 (37mm x 22mm)
contact tips recessed 1/8" (3mm)
S24198-4 1 1/2” x 3/4” (37mm x 19mm)
15° bevel
S24198-5 1-5/8” x 1” (42mm x 24mm)
for reamers
S24198-6 1-5/8” x 1” (42mm x 24mm)
heavy duty
Nozzle Shields
M19267 Nozzle Shield (Fiber)
or
M19558 Nozzle Shield (Ceramic)
Torch Shields
S24432 Torch Shield(for G3494-X Torch, with
Air Blast)
S24432-1 Torch Shield(for G3494-X Torch,
Solid Shield)
S24432-A Torch Shield(for G3494-XA Torch,
with Air Blast)
S24432-A1 Torch Shield(for G3494-XA Torch,
Solid Shield)
Mounting Brackets
M19277 Bracket Arm
M19190 Bracket Arm to Torch Body Insulator
TANDEM MIG TORCH
D-1
MAINTENANCE
D-1
TORCH SHIELD REPLACEMENT
It is important that the torch shield be inspected and
replaced on a routine basis. The torch shields
(S24432, -1, -A, -1A) are designed to protect the more
expensive overmolded assembly of the Tandem torch
from arc and heat induced erosion. The shields must
be inspected and replaced on a routine basis. It is
important to replace burnt, eroded or other wise dam-
aged shields during a routine inspection process.
Care must be taken not to introduce moisture or fluid
between shield and the over molded assembly.
Retained moisture between the two components will
induce erosion of the overmolded assembly. When
replacing or inspecting the torch shield, clean compo-
nents free of oil, dirt and moisture before welding.
(See Figure 5)
a) Turn off power to the welding equipment.
b) Remove the nozzle from the torch.
c) Unscrew and remove the contact tips and dif-
fusers.
d) Using a 5/32" allen wrench, remove the four
screws holding the barrel clamp and then remove
the barrel clamp.
e) Slide the barrel off of the torch.
g) Remove the old torch shield from inside the barrel.
Place a new torch shield in the barrel, being sure
the orientation of the torch shield is correct. There
is a small step in the torch shield that seats in the
barrel. When assembled correctly, the face of the
torch shield will be flush with the end of the barrel.
h) Assembly of the remainder of the torch is the
reverse of the earlier steps.
FIGURE 5
Torch Shield Replacement
TANDEM MIG TORCH
SAFETY PRECAUTIONS
Have qualified personnel do the maintenance
work. If a problem cannot be corrected by
following the instructions, take the equipment to
the nearest Lincoln Field Service Shop for
repair.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
See additional warning information
throughout this operator’s manual.
-----------------------------------------------------------
MAINTENANCE
a) Replace worn contact tips as required.
b) Remove spatter from inside of the gas nozzle and
from the tips after every 20 minutes of arc time, or
as required.
c) Replace the nozzle shield when it exhibits signs of
deterioration.
d) For steel or metal cored electrodes, clean the
cable liners after using approximately 2000 lbs of
electrode. Remove the cables from the wire
feeders and extend them so they are straight. Lay
the cables out on the floor, if possible. Remove
the contact tips from the torch. Using an air hose
and only partial pressure, gently blow out the
cable liners from the gas diffuser end. Flex the
cables over its entire length and again blow out
the cable. Repeat this procedure until no further
dirt comes out.
EXCESSIVE PRESSURE MAY CAUSE THE DIRT
TO FORM A PLUG.
-----------------------------------------------------------
WARNING
CAUTION
D-2
MAINTENANCE
D-2
CONTACT TIP REPLACEMENT
Each application will dictate the frequency of contact
tip replacement. Higher amperage higher duty cycle
operations will require more frequent contact tip
replacement. The condition of the contact tip greatly
effects the welding performance. A routine tip replace-
ment schedule should be established and adhered to.
For general operations contact tips should be
changed at the beginning of every shift.
LINER REPLACEMENT
Wire condition and plant environment as well as wire
consumption rate dictate how often a liner should be
changed. Smaller wire diameter will require a more
frequent change interval than large diameter opera-
tions. For general operations using .045" dia. wire lin-
ers should be changed after approximately 2000 lbs of
wire use.
TANDEM MIG TORCH
E-1
TROUBLESHOOTING
E-1
TANDEM MIG TORCH
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
E-2
TROUBLESHOOTING
E-2
TANDEM MIG TORCH
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
The drive rolls turn, but wire will not feed
or wire feeding is rough.
The arc starts, but during the weld the
arc goes out and wire keeps feeding.
Water leaks from the torch.
Porosity in the weld.
a. Gun cable is kinked and/or twisted.
b. Wire jammed in gun or cable.
c. Incorrect drive rolls and guide tubes.
d. Gun cable liner dirty.
e. Conduit clogged or dirty.
f. Worn drive rolls.
g. Electrode rusty or dirty.
h. Worn or improperly sized cable liner.
i. Partially flashed, melted or improper
contact tip.
a. Loose electrode or work lead connec-
tion.
b. The output of the Power Wave is
being exceeded, and the machine is
"phasing back".
c. The wrong weld program has been
selected.
a. Misassembled torch shield.
b. O-rings on the nozzle are cut, worn or
torn.
c. Loose connections where the cables
enter the torch.
a. The parts to be welded are dirty.
b. The parts to be welded have a surface
coating.
c. The arc length is excessively long.
d. Insufficient shielding gas flow.
e. Gas solenoid not turning on.
f. Loose shielding gas connections.
a. Keep as straight as possible. Inspect
cable and replace if necessary.
b. Remove wire from gun and cable,
then feed in new wire. Check for any
obstructions. Replace the liner if nec-
essary.
c. Be sure the wire diameter being used
matches the sizes of the drive rolls
and guide tubes.
d. Clean or replace liner.
e. Blow the conduit out with compressed
air. Check for obstructions. Replace
conduit if necessary.
f. Replace or reverse split drive rolls.
g. Replace the electrode.
h. Replace cable liner.
i. Replace the contact tip.
a. Verify that all the connections are tight
and are not overheating.
b. Change the welding procedure to
reduce the output current.
c. Make sure the welding program on the
power source matches the wire size
and gas actually being run.
a. Assemble the torch shield properly. It
should be flush with the bottom of the
barrel.
b. Replace the o-rings.
c. Properly connect the cables to the
torch.
a. Remove dirt, oil, lubricants and scale
from the part to be welded.
b. Do not weld painted, plated or insula-
tion-coated parts.
c. Properly set the weld procedure.
Generally arc lengths do not exceed
approximately 1/4".
d. Verify that the torch is being supplied
with 65 scfh.
e. Check that the gas solenoid fully turns
on during welding.
f. Check that all the connections are
sealed and that there are no cuts or
kinks in the shielding gas line.
E-3
TROUBLESHOOTING
E-3
TANDEM MIG TORCH
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
PPOSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Porosity in the weld. (Continued)
The arc length is inconsistent.
There is arcing to the nozzle.
There is arcing between the contact tips
or arc flaring.
g. Wrong shielding gas composition.
h. Lead arc length too short.
i. Water is leaking into the arc.
j. Air is being drafted through the barrel.
k. Weld is too large.
l. Excessive anti-spatter fluid.
m. For installations with an anti-spatter
system, the anti-spatter solenoid may
not be closing completely.
n. For installations without an anti-spat-
ter system, the line may not be
plugged.
a. The contact tip is worn.
b. The liner and/or conduit are dirty or
worn.
c. The drive rolls and guide tubes on the
wire feeder are not properly assem-
bled.
d. The variation in the joint is too large.
e. The electrode or work lead connec-
tions are loose.
f. Only one ground lead is being used.
g. The wrong weld program has been
selected.
a. Spatter build-up is bridging between
the nozzle and contact tips or diffusers
b. The nozzle is too narrow for the appli-
cation.
c. The torch is not insulated from the fix-
ture.
a. Spatter build-up is creating a bridge
between the contact tips.
b. The wire size selection is wrong.
g. Make sure the shielding gas is appro-
priate for the weld procedure.
h. The lead arc should be in the spray or
pulse mode and not in globular or
short arc transfer.
i. Verify that nozzle to torch o-rings are
sealing properly.
j. Check that the o-rings to seal the bar-
rel to the over molded assembly are
sealing properly.
k. Use a trailing gas shield or a nozzle
that supplies a wider coverage of gas
shielding.
l. Use only a minimal amount of anti-
spatter fluid.
m. Verify that the solenoid closes com-
pletely.
n. Make sure the anti-spatter line is
plugged and sealed.
a. The wire should slide freely through
the contact tip. Replace if necessary.
b. Clean the liners and conduit. Replace
if necessary.
c. Make sure the correct size drive rolls
and guide tubes are in the feeder the
wire feeds through without distortion.
d. Improve fixturing and part forming if
necessary, or add seam tracking.
e. Verify that all the connections are tight
and are not overheating.
f. Use an individual ground lead from the
work stud of each power source to the
fixture.
g. Make sure the welding program on the
power source matches the wire size
and gas actually being run.
a. Remove spatter build-up on a regular
basis. Adjust weld procedure to
reduce spatter.
b. Switch to a wider nozzle.
c. Make sure the torch is on an insulated
mount. Use M19190 insulator if neces-
sary.
a. Remove spatter build-up on a regular
basis. Adjust procedure to reduce
spatter.
b. Switch to a larger diameter lead and
trail wire.
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Lincoln Electric Tandem MIG Torch Operating instructions

Lincoln Electric
Brand
Lincoln Electric
Model
Tandem MIG Torch
Category
Welding System
Type
Operating instructions
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